Audi Workshop Service and Repair Manuals

Removing and installing radiator and charge air cooler Special tools and workshop equipment required

t  Engine bung set -VAS 6122-

t  Drip tray for workshop hoist -VAS 6208-

t  Hose clip pliers -VAS 6362-

Removing –  Remove radiator cowl → Chapter. –  Drain coolant → Chapter. –  Remove bumper cover → Rep. gr.63. –  Release fasteners -arrows- and detach air duct -1-.

–  Remove bolts -arrows- and detach air duct -1- from lock carrier.

–  Release fasteners and detach air ducts -1 and 2-.

–  Release hose clips -1 and 2- and detach coolant hoses (top left) from radiator.

–  Release hose clips -1 and 2- and remove air hose. –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-.

–  Remove bolts -arrows-. –  Swivel top edge of radiator slightly to rear. –  Lift radiator, disengage it from bottom mounting points and press it to the rear.

Vehicles with air conditioning:   WARNING Risk of injury caused by refrigerant. The air conditioner refrigerant circuit must not be opened. –  Remove bolts -arrows-.   Caution Danger of damage to refrigerant lines and hoses. Do NOT stretch, kink or bend refrigerant lines and hoses. –  Move condenser to front and place in lock carrier, then secure with cable ties to prevent from dropping.

All vehicles (continued): –  Release fasteners on charge air cooler -1--arrows A-. –  Pull charge air cooler off radiator -2--arrow B- and disengage -arrow C-. –  Take off radiator and charge air cooler. Installing Installation is carried out in the reverse order; note the following: l  Tightening torques → Chapter „Radiator and radiator fans - exploded view“   Note t  If there are slight impressions on the fins, refer to → Chapter. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. –  Vehicles with air conditioner: Install condenser → Rep. gr.87. –  Install air duct on lock carrier → Rep. gr.24. –  Install air hoses with screw-type clips → Fig.. –  Install bumper cover → Rep. gr.63. –  Install radiator cowl → Chapter. –  Fill up with coolant → Anchor.